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TDR1255AE-28199-E5

OWNER’S MANUAL

EAU03338

INTRODUCTION

1Welcome to the Yamaha world of motorcycling!

As the owner of a TDR125, you are benefiting from Yamaha’s vast experience and newest technolo-gy regarding the design and manufacture of high-quality products, which have earned Yamaha a rep-utation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDR125.The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcy-cle, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your motorcycle in the best possiblecondition. If you have any further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

5AE-28199-E5 honbun 7/6/01 10:18 AM Page 1

EAU00005

IMPORTANT MANUAL INFORMATION

1

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander, or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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NOTE:

NOTE:8 This manual should be considered a permanent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.8 Yamaha continually seeks advancements in product design and quality. Therefore, while this

manual contains the most current product information available at the time of printing, theremay be minor discrepancies between your motorcycle and this manual. If you have any ques-tions concerning this manual, please consult your Yamaha dealer.


IMPORTANT MANUAL INFORMATION

1

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGTHIS MOTORCYCLE.


1

TDR125OWNER’S MANUAL

©2001 by Yamaha Motor Co., Ltd.1st Edition, May 2001All rights reserved.

Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan.

EAU03337


EAU00009

TABLE OF CONTENTS

GIVE SAFETY THE RIGHT OF WAY ............... 1-1

DESCRIPTION .................................................. 2-1Left view ......................................................... 2-1Right view ...................................................... 2-2Controls and instruments ............................... 2-3

INSTRUMENT AND CONTROL FUNCTIONS ..... 3-1Main switch/steering lock ............................... 3-1Indicator and warning lights ........................... 3-2Speedometer unit ........................................... 3-3Tachometer .................................................... 3-3Coolant temperature gauge ........................... 3-4Handlebar switches ........................................ 3-4Clutch lever .................................................... 3-6Shift pedal ...................................................... 3-6Brake lever ..................................................... 3-7Brake pedal .................................................... 3-7Fuel tank cap ................................................. 3-7Fuel (except for Switzerland and Austria) ...... 3-8Fuel (for Switzerland and Austria)................... 3-8Catalytic converter (for Switzerland and Austria) ........................ 3-9

2-stroke engine oil ........................................ 3-10Fuel cock ...................................................... 3-11Starter (choke) lever .................................... 3-12Seat .............................................................. 3-12

Helmet holder ............................................... 3-13Adjusting the shock absorber assembly ........3-13YEIS handling precautions ........................... 3-14YPVS ........................................................... 3-15Sidestand ..................................................... 3-15Ignition circuit cut-off system ........................ 3-16

PRE-OPERATION CHECKS ............................ 4-1Pre-operation check list ................................. 4-1

OPERATION AND IMPORTANT RIDING POINTS ............................................................. 5-1

Starting a cold engine .................................... 5-1Starting a warm engine .................................. 5-2Shifting ........................................................... 5-3Recommended shift points (for Switzerland only) ................................... 5-3

Tips for reducing fuel consumption ............... 5-4Engine break-in .............................................. 5-4Parking ........................................................... 5-5

PERIODIC MAINTENANCE AND MINOR REPAIR ............................................................. 6-1

Owner’s tool kit .............................................. 6-1Periodic maintenance and lubrication chart ... 6-2Removing and installing the cowlings and panel ............................................................ 6-5

1

2

3 4

5

6


Checking the spark plug ................................ 6-7Transmission oil ............................................. 6-8Coolant ......................................................... 6-10Cleaning the air filter element ..................... 6-13Adjusting the carburetor ............................... 6-15Adjusting the engine idling speed ................ 6-16Adjusting the throttle cable free play ............ 6-17Tires ............................................................. 6-17Cast wheels ................................................. 6-19Adjusting the clutch lever free play .............. 6-20Adjusting the brake lever free play ............... 6-21Adjusting the brake pedal position ............... 6-22Adjusting the rear brake light switch ............ 6-22Checking the front and rear brake pads ....... 6-23Checking the brake fluid level ...................... 6-24Changing the brake fluid .............................. 6-25Drive chain slack .......................................... 6-25Lubricating the drive chain ........................... 6-26Checking and lubricating the cables ............ 6-27Checking and lubricating the throttle grip and cable ................................................... 6-28

Adjusting the Autolube pump ....................... 6-28Checking and lubricating the brake and shift pedals ................................................. 6-29

Checking and lubricating the brake and clutch levers .................................................6-29

Checking and lubricating the sidestand ....... 6-29

Lubricating the rear suspension ................... 6-30Checking the front fork ................................. 6-30Checking the steering .................................. 6-31Checking the wheel bearings ....................... 6-32Battery .......................................................... 6-32Replacing the fuse ....................................... 6-33Replacing a headlight bulb ........................... 6-34Replacing the tail/brake light bulb ................ 6-35Replacing a turn signal light bulb ................. 6-36Supporting the motorcycle ........................... 6-37Front wheel .................................................. 6-37Rear wheel ................................................... 6-39Troubleshooting ........................................... 6-41Troubleshooting charts ................................ 6-42

MOTORCYCLE CARE AND STORAGE ........... 7-1Care ............................................................... 7-1Storage .......................................................... 7-4

SPECIFICATIONS ............................................ 8-1Conversion table ............................................ 8-5

CONSUMER INFORMATION.............................9-1Identification numbers .................................... 9-1Key identification number ............................... 9-1Vehicle identification number ......................... 9-1Model label ..................................................... 9-2

TABLE OF CONTENTS

7

8

9


1-1

EAU00021

QGIVE SAFETY THE RIGHT OF WAY

1

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-dom. However, they also impose certain limits, which you must accept; even the best motorcycledoes not ignore the laws of physics.

Regular care and maintenance are essential for preserving value and operating condition of yourmotorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performancedepends on being in good shape. Riding under the influence of medication, drugs and alcohol is, ofcourse, out of the question. Motorcycle riders—more than car drivers—must always be at their mentaland physical best. Under the influence of even small amounts of alcohol, there is a tendency to takedangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant syntheticmaterials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This iseven more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-ly—avoiding all dangers, including those caused by others.

Enjoy your ride!


2-1

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DESCRIPTION

2

1. Headlight (page 6-34)2. Fuel cock (page 3-11)3. 2-stroke engine oil tank (page 3-10)4. Helmet holder (page 3-13)5. Starter (choke) lever (page 3-12)

6. YEIS (page 3-14)7. YPVS (page 3-15)

1 2 3 4

567

Left view


2-2

DESCRIPTION

2

8. Owner’s tool kit (page 6-1)9. Fuse (page 6-33)

10. Air filter element (page 6-13)11. Radiator cap (page 6-11)12. Brake pedal (page 3-7, 6-22)13. Coolant reservoir tank (page 6-10)

14. Shock absorber spring preload adjusting ring (page 3-13)

8 9 10 11

121314

Right view


2-3

DESCRIPTION

2

1. Clutch lever (page 3-6, 6-20)2. Left handlebar switches (page 3-4)3. Speedometer unit (page 3-3)4. Coolant temperature gauge (page 3-4)5. Tachometer (page 3-3)

6. Right handlebar switches (page 3-6)7. Brake lever (page 3-7, 6-21)8. Throttle grip (page 6-17, 6-28)9. Fuel tank cap (page 3-7)

10. Main switch/steering lock (page 3-1)

1 2 3 4 5 6 7

8910

Controls and instruments


3-1

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INSTRUMENT AND CONTROL FUNCTIONS

3

EAU00029

Main switch/steering lockThe main switch/steering lock con-trols the ignition and lighting systems,and is used to lock the steering. Thevarious positions are describedbelow.

EAU00036

ONAll electrical systems are suppliedwith power, and the engine can bestarted. The key cannot be removed.

EAU00038

OFFAll electrical systems are off. The keycan be removed.

EAU00040

LOCKThe steering is locked, and all electri-cal systems are off. The key can beremoved.

To lock the steering1. Turn the handlebars all the way

to the left.2. Push the key in from the “OFF”

position, and then turn it to“LOCK” while still pushing it.

3. Remove the key.

To unlock the steeringPush the key in, and then turn it to“OFF” while still pushing it.

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Never turn the key to “OFF” or“LOCK” while the motorcycle ismoving, otherwise the electricalsystems will be switched off,which may result in loss of controlor an accident. Make sure that themotorcycle is stopped before turn-ing the key to “OFF” or “LOCK”.

EAU01574

.. (Parking)The steering is locked, and the tail-lights and auxiliary lights are on, butall other electrical systems are off.The key can be removed.The steering must be locked beforethe key can be turned to “.”.

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Do not use the parking position foran extended length of time, other-wise the battery may discharge.

OFF ON

LO

CK

P

PU

SH

YM

- 8

IGNITION

ONOFF

LOCKPARKING

a b

a. Push.b. Turn.


3-2

EAU03034

Indicator and warning lightsEAU00057

Turn signal indicator light “5”This indicator light flashes when theturn signal switch is pushed to the leftor right.

EAU00063

High beam indicator light “&”This indicator light comes on whenthe high beam of the headlight isswitched on.

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2-stroke engine oil level warninglight “7”This warning light comes on whenthe 2-stroke engine oil level is low.The electrical circuit of the warninglight can be checked according to thefollowing procedure.

1. Set the engine stop switch to"#" and turn the key to "ON".

2. Shift the transmission into theneutral position or pull the clutchlever.

3. Push the start switch. If thewarning light does not come onwhile pushing the start switch,have a Yamaha dealer check theelectrical circuit.

NOTE:Even if the 2-stroke engine oil level issufficient, the warning light may flick-er when riding on a slope or duringsudden acceleration or deceleration,but this is not a malfunction.

EAU00061

Neutral indicator light “N”This indicator light comes on whenthe transmission is in the neutralposition.


3

1 2

341. Turn signal indicator light “5”2. High beam indicator light “&”3. 2-stroke enjine oil level warning light “7”4. Neutral indicator light “N”


3-3


3

EAU01087

Speedometer unitThe speedometer unit is equippedwith a speedometer, an odometerand a tripmeter. The speedometershows riding speed. The odometershows the total distance traveled.The tripmeter shows the distancetraveled since it was last set to zerowith the reset knob. The tripmetercan be used to estimate the distancethat can be traveled with a full tank offuel. This information will enable youto plan future fuel stops.

NOTE:Only for the German model equippedwith a speed limiter:The speed limiter prevents the motor-cycle from exceeding a riding speedof 80 km/h.

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TachometerThe tachometer allows the rider tomonitor the engine speed and keep itwithin the ideal power range.

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Do not operate the engine in thetachometer red zone.Red zone: 10,000 r/min and above

12

34

1

2

1. Speedometer2. Odometer3. Tripmeter4. Reset knob

1. Tachometer2. Red zone


3-4

EAU01652

Coolant temperature gaugeWith the key in the “ON” position, thecoolant temperature gauge indicatesthe temperature of the coolant. Thecoolant temperature varies withchanges in the weather and engineload. If the needle reaches or entersthe red zone, stop the motorcycleand let the engine cool. (See page 6-43 for further instructions.)

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Do not operate the engine if it isoverheated.

EAU00118

Handlebar switchesEAU03898

Light switch “9/'/:”Set this switch to “'” to turn onthe auxiliary light, meter lighting andtaillight. Set the switch to “:” to turnon the headlight also. Set the switchto “9” to turn off all the lights.

EAU03888

Dimmer switch “&/%”Set this switch to “&” for the highbeam and to “%” for the low beam.

EAU03889

Turn signal switch “4/6”To signal a right-hand turn, push thisswitch to “6”. To signal a left-handturn, push this switch to “4”. Whenreleased, the switch returns to thecenter position. To cancel the turnsignal lights, push the switch in afterit has returned to the center position.

EAU00129

Horn switch “*”Press this switch to sound the horn.


3

21

1

23 4

1. Coolant temperature gauge2. Red zone

1. Light switch “9/'/:”2. Dimmer switch “&/%”3. Turn signal switch “4/6”4. Horn switch “*”


3-5


3

EAU00136

Headlight variations

NOTE:Right and left are defined as seen when standing in front of the motorcycle.

3 : High beam light on , 2 : Low beam light on' : Auxiliary light on

1

2

&

&

%

%

Left Right Bulb to be used Destination

3

'

3

2

'

2

3

2

Halogenbulb

Halogenbulb

France Sweden Portugal SpainGreece Belgium GermanySwitzerland Finland Austria

EnglandIreland

12V 60/55W

12V60/55W

12V 35/35W

12V 35/35W


3-6

EAU03890

Engine stop switch “#/$”Set this switch to “#” before startingthe engine. Set this switch to “$” tostop the engine in case of an emer-gency, such as when the motorcycleoverturns or when the throttle cable isstuck.

EAU00143

Start switch “,”Push this switch to crank the enginewith the starter.

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See page 5-1 for starting instruc-tions prior to starting the engine.

EAU00152

Clutch leverThe clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the han-dlebar grip. To engage the clutch,release the lever. The lever shouldbe pulled rapidly and released slowlyfor smooth clutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (See page3-16 for an explanation of the ignitioncircuit cut-off system.)

EAU00157

Shift pedalThe shift pedal is located on the leftside of the engine and is used incombination with the clutch leverwhen shifting the gears of the 6-speed constant-mesh transmissionequipped on this motorcycle.


3 2

1

1

1

1. Engine stop switch “#/$”2. Start switch “,”

1. Shift pedal1. Clutch lever


3-7


3

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Brake leverThe brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the han-dlebar grip.

EAU00162

Brake pedalThe brake pedal is on the right sideof the motorcycle. To apply the rearbrake, press down on the brakepedal.

EAU02935

Fuel tank capTo open the fuel tank capOpen the fuel tank cap lock cover,insert the key into the lock, and thenturn it 1/4 turn clockwise. The lock willbe released and the fuel tank cap canbe opened.

To close the fuel tank cap1. Push the fuel tank cap into posi-

tion with the key inserted in thelock.

2. Turn the key counterclockwise tothe original position, remove it,and then close the lock cover.

1

11

a

b

1. Brake lever 1. Brake pedal 1. Fuel tank cap lock covera. Open.b. Unlock.


3-8

NOTE:The fuel tank cap cannot be closedunless the key is in the lock. In addi-tion, the key cannot be removed if thecap is not properly closed andlocked.

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Make sure that the fuel tank cap isproperly closed before riding. EAU03753

Fuel(except for Switzerland andAustria)Make sure that there is sufficient fuelin the tank. Fill the fuel tank to thebottom of the filler tube as shown.

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8 Do not overfill the fuel tank,otherwise it may overflowwhen the fuel warms up andexpands.

8 Avoid spilling fuel on the hotengine.

EAU03754

Fuel(for Switzerland and Austria)Make sure that there is sufficient fuelin the tank. When refueling, be sureto insert the pump nozzle into the fueltank filler hole and to fill the tank tothe bottom of the filler tube as shown.


3

2

1

1

354

2

1. Filler tube2. Fuel level

1. Pump nozzle2. Fuel tank filler hole3. Filler tube4. Fuel level5. Leaf valve


3-9


3

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8 Do not overfill the fuel tank,otherwise it may overflowwhen the fuel warms up andexpands.

8 Avoid spilling fuel on the hotengine.

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Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted sur-faces or plastic parts.

EAU04206

Your Yamaha engine has beendesigned to use regular unleadedgasoline with a research octane num-ber of 91 or higher. If knocking (orpinging) occurs, use a gasoline of adifferent brand or premium unleadedfuel. Use of unleaded fuel will extendspark plug life and reduce mainte-nance costs.

EAU01084

Catalytic converter(for Switzerland and Austria)This motorcycle is equipped with acatalytic converter in the exhaustchamber.

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The exhaust system is hot afteroperation. Make sure that theexhaust system has cooled downbefore doing any maintenancework.

Recommended fuel:REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:Total amount:

11.0 LReserve amount:

2.2 L


3-10

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The following precautions must beobserved to prevent a fire hazardor other damages.8 Use only unleaded gasoline.

The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

8 Never park the motorcyclenear possible fire hazardssuch as grass or other materi-als that easily burn.

8 Do not allow the engine to idletoo long.

EAU03750

2-stroke engine oilMake sure that there is sufficient oil inthe 2-stroke engine oil tank. Add therecommended 2-stroke engine oil ifnecessary.

NOTE:Make sure that the 2-stroke engineoil tank cap is properly installed.


3

1

1. 2-stroke engine oil tank cap

Recommended oil:Yamalube 2 or equivalent 2-stroke engine oil (JASO grade “FC”, or ISO grades “EG-C” or “EG-D”)

Oil quantity:1.2 L


3-11


3

EAU03050

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions:

OFFWith the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is notrunning.

ONWith the lever in this position, fuelflows to the carburetor. Normal ridingis done with the lever in this position.

RESThis indicates reserve. If you run outof fuel while riding, move the lever tothis position. Fill the tank at the firstopportunity. Be sure to set the leverback to “ON” after refueling!

1

OFF

ON 11

RES

1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES”

OFF: closed position ON: normal position RES: reserve position


3-12

EAU03839

Starter (choke) lever “1”Starting a cold engine requires a rich-er air-fuel mixture, which is suppliedby the starter (choke).Move the lever in direction a to turnon the starter (choke).Move the lever in direction b to turnoff the starter (choke).

EAU01619

SeatTo remove the seat

1. Insert the key into the seat lock,and then turn it clockwise.

2. Pull the seat off.

To install the seat1. Insert the projection on the front

of the seat into the seat holderas shown.

2. Push the rear of the seat down tolock it in place.

3. Turn the key counterclockwise,and then remove it.

NOTE:Make sure that the seat is properlysecured before riding.


3

1a

b

a 1

2

1. Starter (choke) lever “1” a. Unlock. 1. Projection2. Seat holder


3-13


3

EAU00260

Helmet holderTo open the helmet holder, insert thekey into the lock, and then turn thekey as shown.To lock the helmet holder, place it inthe original position, and then removethe key.

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Never ride with a helmet attachedto the helmet holder, since the hel-met may hit objects, causing lossof control and possibly an acci-dent.

EAU00295

Adjusting the shockabsorber assemblyThis shock absorber assembly isequipped with a spring preloadadjusting ring.

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Never attempt to turn an adjustingmechanism beyond the maximumor minimum settings. Adjust the spring preload as follows.

To increase the spring preload andthereby harden the suspension, turnthe adjusting ring in direction a. Todecrease the spring preload andthereby soften the suspension, turnthe adjusting ring in direction b.

NOTE:Align the appropriate notch in theadjusting ring with the position indica-tor on the shock absorber.

a

a

b

1

a. Open. 1. Spring preload adjusting ring


3-14

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This shock absorber containshighly pressurized nitrogen gas.For proper handling, read andunderstand the following informa-tion before handling the shockabsorber. The manufacturer can-not be held responsible for proper-ty damage or personal injury thatmay result from improper han-dling.8 Do not tamper with or attempt

to open the gas cylinder.8 Do not subject the shock

absorber to an open flame orother high heat sources, other-wise it may explode due toexcessive gas pressure.

8 Do not deform or damage thegas cylinder in any way, asthis will result in poor damp-ing performance.

8 Always have a Yamaha dealerservice the shock absorber.

EAU00325

YEIS handling precautionsImproper installation of or damage toany part of the YEIS (YamahaEnergy Induction System) will resultin poor performance. Therefore, han-dle the YEIS air chamber and airchamber hose with special care andimmediately replace any cracked ordamaged parts.

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Do not attempt to modify the YEISin any way.

EAU00027


3 1

123456789

1

1. YEIS1. Position indicator

Setting

Minimum (soft) 1

Standard 4

Maximum (hard) 9


3-15


3

EAU00326

YPVSThis model is equipped with theYPVS (Yamaha Power ValveSystem). This system boosts engineperformance and efficiency by meansof a variable valve in the exhaustport. The YPVS valve is constantlyadjusted in accordance with theengine speed by a computer-con-trolled servomotor.Since the YPVS is an important partof the engine and requires verysophisticated adjustment, have aYamaha dealer, who has the neces-sary professional knowledge andexperience, make this adjustment.

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The YPVS has been set and exten-sively tested at the Yamaha facto-ry. Changing these settings with-out sufficient technical knowledgemay result in poor performance ofor damage to the engine.

YPVS operation noises can be heardin the following instances:8 When the key is turned to “ON”

and the engine is started.8 When the engine stalls with the

key in the “ON” position.EC000024

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If the YPVS does not operate, havea Yamaha dealer check it.

EAU00330

SidestandThe sidestand is located on the leftside of the frame. Raise the side-stand or lower it with your foot whileholding the motorcycle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system,which cuts the ignition in certain situ-ations. (See further down for anexplanation of the ignition circuit cut-off system.)

1

1. YPVS


3-16

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The motorcycle must not be riddenwith the sidestand down, or if thesidestand cannot be properlymoved up (or does not stay up),otherwise the sidestand could con-tact the ground and distract theoperator, resulting in a possibleloss of control. Yamaha’s ignitioncircuit cut-off system has beendesigned to assist the operator infulfilling the responsibility of rais-ing the sidestand before startingoff. Therefore, check this systemregularly as described below andhave a Yamaha dealer repair it if itdoes not function properly.

EAU03720

Ignition circuit cut-off systemThe ignition circuit cut-off system(comprising the sidestand switch,clutch switch and neutral switch) hasthe following functions.8 It prevents starting when the

transmission is in gear and thesidestand is up, but the clutchlever is not pulled.

8 It prevents starting when thetransmission is in gear and theclutch lever is pulled, but thesidestand is still down.

8 It cuts the running engine whenthe transmission is in gear andthe sidestand is moved down.

Periodically check the operation ofthe ignition circuit cut-off systemaccording to the following procedure.

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If a malfunction is noted, have aYamaha dealer check the systembefore riding.


3


3-17


3

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “#”.3. Turn the key to “ON”. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

The neutral switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The sidestand switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

NO

NOTE:This check is most reliable if performed witha warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO


4-1

EAU01114

PRE-OPERATION CHECKS

4

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-ough visual inspection, to check the following points before each ride.

EAU03439

Pre-operation check list

ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-7–3-9

2-stroke engine oil• Check oil level in oil tank.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

3-10

Transmission oil • Check oil level in transmission case.• If necessary, add recommended oil to specified level. 6-8–6-10

Coolant• Check coolant level in reservoir.• If necessary, add recommended coolant to specified level.• Check cooling system for leakage.

6-10–6-13

Front brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check lever free play.• Adjust if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

3-7, 6-21, 6-23–6-24


4-2


4

Rear brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

3-7, 6-22–6-24

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

3-6, 6-20–6-21

Throttle grip• Make sure that operation is smooth.• Check free play.• If neccessary, have Yamaha dealer make adjustment or lubricate.

6-17, 6-28

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-27

Drive chain

• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

6-25–6-27

Wheels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

6-17–6-19

Brake and shift pedals • Make sure that operation is smooth.• Lubricate pedal pivoting points if necessary. 6-29

Brake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 6-29

Sidestand • Make sure that operation is smooth.• Lubricate pivot if necessary. 6-29–6-30

ITEM CHECKS PAGE


4-3


4

NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in avery short time; and the added safety it assures is more than worth the time involved.

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If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-ing the motorcycle.

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. —

Instruments, lights, signals and switches

• Check operation. • Correct if necessary. 3-2–3-6

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-15–3-17

ITEM CHECKS PAGE


5-1

EAU00372

OPERATION AND IMPORTANT RIDING POINTS

5

EAU00373

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8 Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealerregarding any control or func-tion that you do not thorough-ly understand.

8 Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

8 Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU04271

Starting a cold engineIn order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:8 The transmission is in the neutral

position.8 The transmission is in gear with

the clutch lever pulled and thesidestand up.

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8 Before starting the engine,check the function of the igni-tion circuit cut-off systemaccording to the proceduredescribed on page 3-17.

8 Never ride with the sidestanddown.

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switchis set to “#”.

3. Shift the transmission into theneutral position.

NOTE:When the transmission is in the neu-tral position, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit.

4. Turn the starter (choke) on andcompletely close the throttle.(See page 3-12 for starter(choke) operation.)

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank theengine more than 10 seconds on anyone attempt.


5-2


5

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The 2-stroke engine oil level warn-ing light should come on when thestart switch is pushed, and itshould go off when the startswitch is released. If the warninglight flickers or remains on afterstarting, immediately stop theengine, and then check the 2-stroke engine oil level and thevehicle for oil leakage. If neces-sary, add 2-stroke engine oil, andthen check the warning light again.If the warning light does not comeon when pushing the start switch,or if it does not go off after startingwith sufficient 2-stroke engine oil,have a Yamaha dealer check theelectrical circuit.

6. After starting the engine, movethe starter (choke) lever backhalfway.

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For maximum engine life, neveraccelerate hard when the engine iscold!

7. When the engine is warm, turnthe starter (choke) off.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.

EAU01258

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is notrequired when the engine is warm.


5-3


5

EAU00423

ShiftingShifting gears lets you control theamount of engine power available forstarting off, accelerating, climbinghills, etc.The gear positions are shown in theillustration.

NOTE:To shift the transmission into the neu-tral position, press the shift pedaldown repeatedly until it reaches theend of its travel, and then slightlyraise it.

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8 Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for longdistances. The transmission isproperly lubricated only whenthe engine is running.Inadequate lubrication maydamage the transmission.

8 Always use the clutch whilechanging gears to avoid dam-aging the engine, transmis-sion, and drive train, which arenot designed to withstand theshock of forced shifting.

EAU02937

Recommended shift points(for Switzerland only)The recommended shift points duringacceleration are shown in the tablebelow.

NOTE:When shifting down two gears at atime, reduce the speed accordingly(e.g., down to 35 km/h when shiftingfrom 5th to 3rd gear).

65432

1N

11. Shift pedalN. Neutral position

Shift point(km/h)

1st → 2nd2nd → 3rd3rd → 4th4th → 5th5th → 6th

2030405060


5-4


5

EAU00424

Tips for reducing fuel consumptionFuel consumption depends largely onyour riding style. Consider the follow-ing tips to reduce fuel consumption:8 Thoroughly warm up the engine.8 Turn the starter (choke) off as

soon as possible.8 Shift up swiftly, and avoid high

engine speeds during accelera-tion.

8 Do not rev the engine while shift-ing down, and avoid high enginespeeds with no load on theengine.

8 Turn the engine off instead of let-ting it idle for an extended lengthof time (e.g., in traffic jams, attraffic lights or at railroad cross-ings).

EAU00436

Engine break-inThere is never a more important peri-od in the life of your engine than theperiod between 0 and 1,000 km. Forthis reason, you should read the fol-lowing material carefully.Since the engine is brand new, donot put an excessive load on it for thefirst 1,000 km. The various parts inthe engine wear and polish them-selves to the correct operating clear-ances. During this period, prolongedfull-throttle operation or any conditionthat might result in engine overheat-ing must be avoided.

EAU00453

0–500 km8 Avoid prolonged operation above

6,000 r/min.8 After every hour of operation,

stop the engine, and then let itcool for five to ten minutes.

8 Vary the engine speed from timeto time. Do not operate theengine at one set throttle posi-tion.

500–1,000 km8 Avoid prolonged operation

above 7,000 r/min.8 Rev the engine freely through

the gears, but do not use fullthrottle at any time.

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After 1,000 km of operation, thetransmission oil must be changed.


5-5


5

1,000 km and beyondThe vehicle can now be operatednormally.

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8 Keep the engine speed out ofthe tachometer red zone.

8 If any engine trouble shouldoccur during the engine break-in period, immediately have aYamaha dealer check the vehi-cle.

EAU00458

ParkingWhen parking, stop the engine,remove the key from the main switch,and then turn the fuel cock lever to“OFF”.

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8 Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likelyto touch them.

8 Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

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Never park in an area where thereare fire hazards such as grass orother flammable materials.


6-1

EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

6

EAU00464

Safety is an obligation of the owner.Periodic inspection, adjustment andlubrication will keep your vehicle inthe safest and most efficient condi-tion possible. The most importantpoints of inspection, adjustment, andlubrication are explained on the fol-lowing pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as ageneral guide under normal ridingconditions. However, DEPENDINGON THE WEATHER, TERRAIN,GEOGRAPHICAL LOCATION, ANDINDIVIDUAL USE, THE MAINTE-NANCE INTERVALS MAY NEED TOBE SHORTENED.

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If you are not familiar with motor-cycle maintenance work, have aYamaha dealer do it for you.

EAU03758

Owner’s tool kitThe owner’s tool kit is located underthe seat. (See page 3-12 for seatremoval and installation procedures.)The service information included inthis manual and the tools provided inthe owner’s tool kit are intended toassist you in the performance of pre-ventive maintenance and minorrepairs. However, additional toolssuch as a torque wrench may be nec-essary to perform certain mainte-nance work correctly.

NOTE:If you do not have the tools or experi-ence required for a particular job,have a Yamaha dealer perform it foryou.

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Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicleunsafe for use. Consult a Yamahadealer before attempting anychanges.

1

1. Owner’s tool kit


6-2


6

EAU03686

Periodic maintenance and lubrication chartNOTE:8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km.8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and

technical skills.

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km) ANNUAL

CHECK1 6 12 18 24

1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

2 Spark plug • Replace. √ √ √ √ √

3 Air filter element• Clean. √ √• Replace. √ √

4 Clutch • Check operation.• Adjust. √ √ √ √ √

5 * Front brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

6 * Rear brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

7 * Brake hoses• Check for cracks or damage. √ √ √ √ √• Replace. (See NOTE on page 6-4.) Every 4 years

8 * Wheels • Check runout and for damage. √ √ √ √


6-3


6

9 * Tires

• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

√ √ √ √ √

10 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

11 * Swingarm• Check operation and for excessive play. √ √ √ √• Lubricate with lithium-soap-based grease. Every 24,000 km

12 Drive chain• Check chain slack.• Make sure that the rear wheel is properly aligned.• Clean and lubricate.

Every 1,000 km and after washingthe motorcycle or riding in the rain.

13 * Steering bearings• Check bearing play and steering for roughness. √ √ √ √ √• Lubricate with lithium-soap-based grease. Every 24,000 km

14 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √

15 Sidestand • Check operation.• Lubricate. √ √ √ √ √

16 * Sidestand switch • Check operation. √ √ √ √ √ √

17 * Front fork • Check operation and for oil leakage. √ √ √ √

18 *Shock absorber assembly • Check operation and shock absorber for oil leakage. √ √ √ √

19 * Carburetor • Check starter (choke) operation.• Adjust engine idling speed. √ √ √ √ √ √

20 * Autolube pump • Check operation.• Bleed if necessary. √ √ √ √


CHECK1 6 12 18 24


6-4


6

EAU03884

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake service9 Regularly check and, if necessary, correct the brake fluid level.9 Every two years replace the internal components of the brake master cylinders and calipers, and change the

brake fluid.9 Replace the brake hoses every four years and if cracked or damaged.

21 Transmission oil• Check oil level. √ √ √ √ √ √• Change. √ √

22 * Cooling system• Check coolant level and vehicle for coolant leakage. √ √ √ √ √• Change. Every 3 years

23 *Front and rear brake switches • Check operation. √ √ √ √ √ √

24 Moving parts and cables • Lubricate. √ √ √ √ √

25 *Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √ √ √ √ √


CHECK1 6 12 18 24


6-5


6

EAU03624

Removing and installing thecowlings and panelThe cowlings and panel shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. Refer to this sectioneach time a cowling or the panelneeds to be removed and installed.

1 11

1. Cowling A 1. Cowling B 1. Panel A


6-6


6

EAU03745

Cowlings A and BTo remove one of the cowlings:

1. Remove the seat. (See page 3-12 for seat removal and instal-lation procedures.)

2. Remove the radiator cover byremoving the screws.

3. Remove the screws, and thenpull the cowling off as shown.

To install the cowling1. Place the cowling in the original

position, and then install thescrews.

2. Install the radiator cover byinstalling the screws.

3. Install the seat.

EAU02993

Panel ATo remove the panel


2. Remove the screws, and thenpull the panel off as shown.

To install the panel1. Place the panel in the original

position, and then install thescrews.

2. Install the seat.

2

1

1

1

2

1. Radiator cover2. Screw (×2)

1. Screw (×5) 1. Panel A2. Screw (×2)


6-7


6

EAU01833

Checking the spark plugThe spark plug is an importantengine component, which is easy tocheck. Since heat and deposits willcause any spark plug to slowly erode,the spark plug should be removedand checked in accordance with theperiodic maintenance and lubricationchart. In addition, the condition of thespark plug can reveal the condition ofthe engine.

To remove the spark plug1. Remove the spark plug cap.

2. Remove the spark plug asshown, with the spark plugwrench included in the owner’stool kit.

To check the spark plug1. Check that the porcelain insula-

tor around the center electrodeof the spark plug is a medium-to-light tan (the ideal color when themotorcycle is ridden normally).

NOTE:If the spark plug shows a distinctlydifferent color, the engine could bedefective. Do not attempt to diagnosesuch problems yourself. Instead,have a Yamaha dealer check themotorcycle.

2. Check the spark plug for elec-trode erosion and excessive car-bon or other deposits, andreplace it if necessary.

1 1

1. Spark plug cap 1. Spark plug wrench

Specified spark plug:BR9ES (NGK)


6-8


6

To install the spark plug1. Measure the spark plug gap with

a wire thickness gauge and, ifnecessary, adjust the gap tospecification.

2. Clean the surface of the sparkplug gasket and its mating sur-face, and then wipe off any grimefrom the spark plug threads.

3. Install the spark plug with thespark plug wrench, and thentighten it to the specified torque.

NOTE:If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is1/4–1/2 turn past finger tight.However, the spark plug should betightened to the specified torque assoon as possible.

4. Install the spark plug cap.

EAU04272

Transmission oil Transmission oil

The transmission oil level should bechecked before each ride. In addition,the transmission oil must be changedat the intervals specified in the peri-odic maintenance and lubricationchart.

To check the transmission oil level1. Place the motorcycle on a level

surface and hold it in an uprightposition.

NOTE:Make sure that the motorcycle ispositioned straight up when checkingthe oil level. A slight tilt to the sidecan result in a false reading.

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

a

a. Spark plug gap

Spark plug gap:0.7–0.8 mm

Tightening torque:Spark plug:

20 Nm (2.0 m0kgf)


6-9


6

3. Wait a few minutes until the oilsettles, and then check the oillevel through the check windowlocated at the right side of thecrankcase.

NOTE:The transmission oil should be at orabove the minimum level mark.

4. If the oil is below the minimumlevel mark, remove the oil fillercap, add sufficient oil of the rec-ommended type to raise it to thecorrect level, and then install andtighten the cap.

To change the transmission oil1. Start the engine, warm it up for

several minutes, and then turn itoff.

2. Place an oil pan under the trans-mission to collect the used oil.

3. Remove the oil filler cap anddrain bolt to drain the oil from thetransmission.

4. Install the transmission oil drainbolt, and then tighten it to thespecified torque.

5. Add the specified amount of therecommended transmission oil,and then install and tighten theoil filler cap.

12

1

1

1. Check window2. Minimum level mark

1. Oil filler cap 1. Transmission oil drain bolt

Tightening torque:Transmission oil drain bolt:

15 Nm (1.5 m0kgf)


6-10


6

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8 In order to prevent clutch slip-page (since the transmissionoil also lubricates the clutch),do not mix any chemical addi-tives with the oil.

8 Make sure that no foreignmaterial enters the transmis-sion.

6. Start the engine, and then let itidle for several minutes whilechecking the transmission for oilleakage. If oil is leaking, immedi-ately turn off the engine andcheck for the cause.

EAU03761

CoolantTo check the coolant level

1. Place the motorcycle on a levelsurface and hold it in an uprightposition.

NOTE:8 The coolant level must be

checked on a cold engine sincethe level varies with engine tem-perature.

8 Make sure that the motorcycle isposit ioned straight up whenchecking the coolant level. Aslight tilt to the side can result ina false reading.

2. Check the coolant level in thecoolant reservoir.

NOTE:The coolant should be between theminimum and maximum level marks.

3. If the coolant is at or below theminimum level mark, open thereservoir cap, add coolant to themaximum level mark, and thenclose the reservoir cap.

12

1. Maximum level mark2. Minimum level mark

Recommended transmission oil:See page 8-1.

Oil quantity:Periodic oil change:

0.75 LTotal amount (dry transmission):

0.8 L


6-11


6

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Never attempt to remove the radia-tor cap when the engine is hot.

NOTE:If the engine overheats, see page 6-43 for further instructions.

EAU03746

To change the coolant1. Place the motorcycle on a level

surface and let the engine cool ifnecessary.


3. Remove cowling B. (See page 6-6 for cowling removal andinstallation procedures.)

4. Remove the radiator cap.EW000067

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Never attempt to remove the radia-tor cap when the engine is hot.

5. Place a container under theengine to collect the usedcoolant.

6. Remove the coolant drain boltand disconnect the hose on theside of the reservoir to drain thereservoir.

7. After the coolant is completelydrained, thoroughly flush thecooling system with clean tapwater.

8. Install the coolant drain bolt, andthen tighten it to the specifiedtorque.

1

1

1. Radiator cap 1. Coolant drain bolt


6-12


6

NOTE:Check the washer for damage andreplace it if necessary.

9. Connect the hose to the coolantreservoir.

10. Pour the recommended coolantinto the radiator until it is full.

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8 If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

8 If water has been used insteadof coolant, replace it withcoolant as soon as possible,otherwise the engine may notbe sufficiently cooled and thecooling system will not be pro-tected against frost and corro-sion.

8 If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possi-ble, otherwise the effective-ness of the coolant will bereduced.

11. Install the radiator cap, start theengine, let it idle for several min-utes, and then turn it off.

1

1. Hose

Tightening torque:Coolant drain bolt:

8 Nm (0.8 m0kgf)

Antifreeze/water mixture ratio:1:1

Recommended antifreeze:High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Coolant quantity:Total amount:

1.05 LCoolant reservoir capacity:

0.35 L


6-13


612. Remove the radiator cap to

check the coolant level in theradiator. If necessary, add suffi-cient coolant until it reaches thetop of the radiator, and theninstall the radiator cap.

13. Check the coolant level in thereservoir. If necessary, removethe coolant reservoir cap byremoving the screw and retainer,add coolant to the maximumlevel mark, and then install thecoolant reservoir cap and retain-er by installing the screw.

14. Start the engine, and then checkthe vehicle for coolant leakage. Ifcoolant is leaking, have aYamaha dealer check the cool-ing system.

15. Install the cowling and the seat.

EAU03747

Cleaning the air filter elementThe air filter element should becleaned at the intervals specified inthe periodic maintenance and lubrica-tion chart. Clean the air filter elementmore frequently if you are riding inunusually wet or dusty areas.


2. Remove cowlings A and B. (Seepage 6-6 for cowling removaland installation procedures.)

3. Remove the fuel tank bolt.

21

45

3 1

1. Coolant reservoir tank cap2. Retainer3. Screw4. Maximum level mark5. Minimum level mark

1. Bolt


6-14


6

4. Lift the front of the fuel tank toposition the fuel tank away fromthe air filter case. (Do not discon-nect the fuel hoses!)

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8 Make sure that the fuel tank iswell supported.

8 Do not tilt or pull the fuel tanktoo much, otherwise the fuelhoses may come loose, whichcould cause fuel leakage. 5. Remove the relays by pulling

them off their holders, and the airfilter case cover by removing thescrews.

6. Pull the sponge material out,clean it with solvent, and thensqueeze the remaining solventout.

7. Apply oil of the recommendedtype to the entire surface of thesponge material, and thensqueeze the excess oil out.

NOTE:The sponge material should be wetbut not dripping.

1

3 3

2

1

1. Relay (×2)2. Air filter case cover3. Screw (×7)

1. Sponge material

Recommended oil:2-stroke engine oil


6-15


6

8. Insert the sponge material intothe air filter case.

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8 Make sure that the air filter ele-ment is properly seated in theair filter case.

8 The engine should never beoperated without the air filterelement installed, otherwisethe piston and/or cylinder maybecome excessively worn.

9. Install the air filter case cover byinstalling the screws, and theninstall the relays.

10. Place the fuel tank in the originalposition, and then install the bolt.

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Make sure that the fuel hoses andvacuum hose are properly con-nected and routed, and notpinched. Replace any damagedhoses.

11. Install the seat and the cowlings.

EAU00629

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires very sophisti-cated adjustment. Therefore, mostcarburetor adjustments should be leftto a Yamaha dealer, who has thenecessary professional knowledgeand experience. The adjustmentdescribed in the following section,however, may be serviced by theowner as part of routine mainte-nance.

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The carburetor has been set andextensively tested at the Yamahafactory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-mance of or damage to the engine.


6-16


6

EAU00632

Adjusting the engine idlingspeedThe engine idling speed must bechecked and, if necessary, adjustedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Start the engine and warm it upfor several minutes at1,000–2,000 r/min while occa-sionally revving it to 4,000–5,000r/min.

NOTE:The engine is warm when it quicklyresponds to the throttle.

2. Check the engine idling speedand, if necessary, adjust it tospecification by turning the throt-tle stop screw. To increase theengine idling speed, turn thescrew in direction a. Todecrease the engine idlingspeed, turn the screw in directionb.

NOTE:If the specified idling speed cannotbe obtained as described above,have a Yamaha dealer make theadjustment.b a

1

1. Throttle stop screw

Engine idling speed:1,300 – 1,500 r/min1,400 – 1,500 r/min (A,CH only)


6-17


6

EAU00634

Adjusting the throttle cablefree playThe throttle cable free play shouldmeasure 3–5 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, adjust itas follows.

NOTE:The engine idling speed must be cor-rectly adjusted before checking andadjusting the throttle cable free play.

1. Loosen the locknut.2. To increase the throttle cable

free play, turn the adjusting nutin direction a. To decrease thethrottle cable free play, turn theadjusting nut in direction b.

3. Tighten the locknut.

EAU04287

TiresTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

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8 The tire air pressure must bechecked and adjusted on coldtires (i.e., when the tempera-ture of the tires equals theambient temperature).

8 The tire air pressure must beadjusted in accordance withthe riding speed and with thetotal weight of rider, passen-ger, cargo, and accessoriesapproved for this model.

a 2

1b

a

a. Free play 1. Locknut2. Adjusting nut


6-18


6

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Because loading has an enormousimpact on the handling, braking,performance and safety character-istics of your motorcycle, youshould keep the following precau-tions in mind.8 NEVER OVERLOAD THE

MOTORCYCLE! Operation ofan overloaded motorcycle mayresult in tire damage, loss ofcontrol, or severe injury. Makesure that the total weight ofrider, passenger, cargo, andaccessories does not exceedthe specified maximum loadfor the vehicle.

8 Do not carry along looselypacked items, which can shiftduring a ride.

8 Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

8 Adjust the suspension and tireair pressure with regard to theload.

8 Check the tire condition andair pressure before each ride.

Tire inspectionThe tires must be checked beforeeach ride. If the center tread depthreaches the specified limit, if the tirehas a nail or glass fragments in it, orif the sidewall is cracked, have aYamaha dealer replace the tire imme-diately.

NOTE:The tire tread depth limits may differfrom country to country. Always com-ply with the local regulations.

1

a

1. Tire side walla. Tread depth

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg175 kPa

(1.75 kgf/cm2,1.75 bar)

200 kPa(2.00 kgf/cm2,

2.00 bar)

90 kg–maximum175 kPa

(1.75 kgf/cm2,1.75 bar)

225 kPa(2.25 kgf/cm2,

2.25 bar)

Maximum load*180 kg

179 kg (CH, A)

* Total weight of rider, passenger, cargo and accessories

Minimum tire tread depth (front and rear)

1.6 mm


6-19


6

Tire informationThis motorcycle is equipped with castwheel and tubeless tires.

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8 The front and rear tires shouldbe of the same make anddesign, otherwise the handlingcharacteristics of the motorcy-cle cannot be guaranteed.

8 After extensive tests, only thetires listed below have beenapproved for this model byYamaha Motor Co., Ltd.

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8 Have a Yamaha dealer replaceexcessively worn tires.Besides being illegal, operat-ing the motorcycle with exces-sively worn tires decreasesriding stability and can lead toloss of control.

8 The replacement of all wheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, whohas the necessary profession-al knowledge and experience.

FRONT

Manufacturer Size Type

BRIDGESTONE100/90-18 56P

TW53100/90-18 M/C 56P

DUNLOP100/90-18 56P

D602F100/90-18 M/C 56P

REAR

Manufacturer Size Type

BRIDGESTONE130/80-17 65P

TW54130/80-17 M/C 65P

DUNLOP130/80-17 65P

D602130/80-17 M/C 65P

EAU03773

Cast wheelsTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified wheels.8 The wheel rims should be

checked for cracks, bends orwarpage before each ride. If anydamage is found, have aYamaha dealer replace thewheel. Do not attempt even thesmallest repair to the wheel. Adeformed or cracked wheel mustbe replaced.

8 The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced.An unbalanced wheel can resultin poor performance, adversehandling characteristics, and ashortened tire life.

8 Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” forit to develop its optimal charac-teristics.


6-20


6

EAU00694

Adjusting the clutch leverfree playThe clutch lever free play shouldmeasure 10–15 mm as shown.Periodically check the clutch leverfree play and, if necessary, adjust itas follows.

1. Loosen the locknut at the clutchlever.

2. To increase the clutch lever freeplay, turn the adjusting bolt indirection a. To decrease theclutch lever free play, turn theadjusting bolt in direction b.

3. If the specified clutch lever freeplay could be obtained asdescribed above, tighten thelocknut and skip the rest of theprocedure, otherwise proceed asfollows.

4. Fully turn the adjusting bolt at theclutch lever in direction a toloosen the clutch cable.

5. Loosen the locknut at thecrankcase.

6. To increase the clutch lever freeplay, turn the adjusting nut indirection a. To decrease theclutch lever free play, turn theadjusting nut in direction b.

a

b1 2

c

b

a

12

1. Locknut (clutch lever)2. Adjusting boltc. Free play

1. Locknut (crankcase)2. Adjusting nut

7. Tighten the locknut at the clutchlever and the crankcase.


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EAU00696

Adjusting the brake leverfree playThe brake lever free play shouldmeasure 2–5 mm as shown.Periodically check the brake leverfree play and, if necessary, adjust itas follows.

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting bolt indirection a. To decrease thebrake lever free play, turn theadjusting bolt in direction b.

3. Tighten the locknut.

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8 After adjusting the brake leverfree play, check the free playand make sure that the brakeis working properly.

8 A soft or spongy feeling in thebrake lever can indicate thepresence of air in thehydraulic system. If there is airin the hydraulic system, havea Yamaha dealer bleed thesystem before operating themotorcycle. Air in thehydraulic system will diminishthe braking performance,which may result in loss ofcontrol and an accident.

1

2

b

c

a

1. Locknut2. Adjusting boltc. Free play


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EAU00712

Adjusting the brake pedalpositionThe top of the brake pedal should bepositioned approximately 23 mmbelow the top of the footrest asshown. Periodically check the brakepedal position and, if necessary,have a Yamaha dealer adjust it.

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A soft or spongy feeling in thebrake pedal can indicate the pres-ence of air in the hydraulic system.If there is air in the hydraulic sys-tem, have a Yamaha dealer bleedthe system before operating themotorcycle. Air in the hydraulicsystem will diminish the brakingperformance, which may result inloss of control and an accident.

EAU00713

Adjusting the rear brake lightswitchThe rear brake light switch, which isactivated by the brake pedal, is prop-erly adjusted when the brake lightcomes on just before braking takeseffect. If necessary, adjust the brakelight switch as follows.Turn the adjusting nut while holdingthe rear brake light switch in place.To make the brake light come on ear-lier, turn the adjusting nut in directiona. To make the brake light come onlater, turn the adjusting nut in direc-tion b.

a

1ba

1

2

1. Footresta. Brake pedal position

1. Rear brake light switch2. Adjusting nut


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EAU00721

Checking the front and rearbrake padsThe front and rear brake pads mustbe checked for wear at the intervalsspecified in the periodic maintenanceand lubrication chart.

EAU00725

Front brake padsEach front brake pad is provided witha wear indicator groove, which allowsyou to check the brake pad wearwithout having to disassemble thebrake. To check the brake pad wear,check the wear indicator groove. If abrake pad has worn to the point thatthe wear indicator groove has almostdisappeared, have a Yamaha dealerreplace the brake pads as a set.

EAU00728

Rear brake padsEach rear brake pad is provided witha wear indicator, which allows you tocheck the brake pad wear withouthaving to disassemble the brake. Tocheck the brake pad wear, check theposition of the wear indicator whileapplying the brake. If a brake padhas worn to the point that the wearindicator almost touches the brakedisc, have a Yamaha dealer replacethe brake pads as a set.

1

1

1. Wear indicator groove 1. Wear indicator

REARFRONT


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EAU03776

Checking the brake fluidlevelInsufficient brake fluid may allow airto enter the brake system, possiblycausing it to become ineffective.Before riding, check that the brakefluid is above the minimum level markand replenish if necessary. A lowbrake fluid level may indicate wornbrake pads and/or brake systemleakage. If the brake level is low, besure to check the brake pads forwear and the brake system for leak-age.

Observe these precautions:8 When checking the fluid level,

make sure that the top of thebrake fluid reservoir is level.

8 Use only the recommended qual-ity brake fluid, otherwise the rub-ber seals may deteriorate, caus-ing leakage and poor brakingperformance.

8 Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking perfor-mance.

8 Be careful that water does notenter the brake fluid reservoirwhen refilling. Water will signifi-cantly lower the boiling point ofthe fluid and may result in vaporlock.

8 Brake fluid may deteriorate paint-ed surfaces or plastic parts.Always clean up spilled fluidimmediately.

8 As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, ifthe brake fluid level goes downsuddenly, have a Yamaha dealercheck the cause.

1 LOWER

1 LOWERUPPER

1. Minimum level mark 1. Minimum level mark

Recommended brake fluid: DOT 4

FRONT REAR


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EAU03976

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addi-tion, have the oil seals of the mastercylinders and calipers as well as thebrake hoses replaced at the intervalslisted below or whenever they aredamaged or leaking.8 Oil seals: Replace every two

years.8 Brake hoses: Replace every four

years.

EAU00744

Drive chain slackThe drive chain slack should bechecked before each ride and adjust-ed if necessary.

To check the drive chain slack1. Place the motorcycle on a level


NOTE:When checking and adjusting thedrive chain slack, the motorcycleshould be positioned straight up andthere should be no weight on it.

2. Shift the transmission into theneutral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain,and then measure the drivechain slack as shown.

4. If the drive chain slack is incor-rect, adjust it as follows.

a

a. Drive chain slack

Drive chain slack:25–40 mm


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EAU03752

To adjust the drive chain slack1. Loosen the axle nut, then loosen

the locknut at each end of theswingarm.

2. To tighten the drive chain, turnthe adjusting nut at each end ofthe swingarm in direction a. Toloosen the drive chain, turn theadjusting nut at each end of theswingarm in direction b, andthen push the rear wheel for-ward.

NOTE:Using the alignment marks on eachside of the swingarm, make sure thatboth adjusting nuts are in the sameposition for proper wheel alignment.

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Improper drive chain slack willoverload the engine as well asother vital parts of the motorcycleand can lead to chain slippage orbreakage. To prevent this fromoccurring, keep the drive chainslack within the specified limits.

3. Tighten the locknuts, and thentighten the axle nut to the speci-fied torque.

EAU03006

Lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quicklywear out, especially when riding industy or wet areas. Service the drivechain as follows.

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The drive chain must be lubricatedafter washing the motorcycle orriding in the rain.

1. Clean the drive chain withkerosene and a small soft brush.

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To prevent damaging the O-rings,do not clean the drive chain withsteam cleaners, high-pressurewashers or inappropriate solvents.

1

4

2 3

a

b

1. Axle nut2. Locknut3. Adjusting nut4. Alignment marks

Tightening torque:Axle nut:

104 Nm (10.4 m0kgf)


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2. Wipe the drive chain dry.3. Thoroughly lubricate the drive

chain with a special O-ring chainlubricant.

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Do not use engine oil or any otherlubricants for the drive chain, asthey may contain substances thatcould damage the O-rings.

EAU02962

Checking and lubricating thecablesThe operation of all control cablesand the condition of the cablesshould be checked before each ride,and the cables and cable endsshould be lubricated if necessary. Ifa cable is damaged or does not movesmoothly, have a Yamaha dealercheck or replace it.

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Damage to the outer sheath mayinterfere with proper cable opera-tion and will cause the inner cableto rust. Replace a damaged cableas soon as possible to preventunsafe conditions.

Recommended lubricant:Engine oil


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EAU04034

Checking and lubricating thethrottle grip and cableThrottle grip and cable, checking and lubricating

The operation of the throttle gripshould be checked before each ride.In addition, the cable should be lubri-cated or replaced at the intervalsspecified in the periodic maintenancechart.

EAU00774

Adjusting the AutolubepumpThe Autolube pump is a vital andsophisticated component of theengine, which must be adjusted by aYamaha dealer at the intervals speci-fied in the periodic maintenance andlubrication chart.


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6

EAU03370

Checking and lubricating thebrake and shift pedalsThe operation of the brake and shiftpedals should be checked beforeeach ride, and the pedal pivotsshould be lubricated if necessary.

EAU03164

Checking and lubricating thebrake and clutch leversThe operation of the brake and clutchlevers should be checked beforeeach ride, and the lever pivots shouldbe lubricated if necessary.

EAU03165

Checking and lubricating thesidestandThe operation of the sidestandshould be checked before each ride,and the sidestand pivot and metal-to-metal contact surfaces should belubricated if necessary.

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If the sidestand does not move upand down smoothly, have aYamaha dealer check or repair it.

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)



6-30


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EAU03166

Lubricating the rear suspensionRear suspension, lubricating

The pivoting points of the rear sus-pension must be lubricated at theintervals specified in the periodicmaintenance and lubrication chart.

EAU02939

Checking the front forkThe condition and operation of thefront fork must be checked as followsat the intervals specified in the peri-odic maintenance and lubricationchart.

To check the conditionEW000115

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Securely support the motorcycleso that there is no danger of itfalling over.

Check the inner tubes for scratches,damage and excessive oil leakage.




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To check the operation1. Place the motorcycle on a level


2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses andrebounds smoothly.

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If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check orrepair it.

EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the opera-tion of the steering must be checkedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Place a stand under the engineto raise the front wheel off theground.

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Securely support the motorcycleso that there is no danger of itfalling over.

2. Hold the lower ends of the frontfork legs and try to move themforward and backward. If anyfree play can be felt, have aYamaha dealer check or repairthe steering.


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EAU01144

Checking the wheel bearingsThe front and rear wheel bearingsmust be checked at the intervalsspecified in the periodic maintenanceand lubrication chart. If there is playin the wheel hub or if the wheel doesnot turn smoothly, have a Yamahadealer check the wheel bearings.

EAU00800

BatteryThis motorcycle is equipped with asealed-type (MF) battery, which doesnot require any maintenance. Thereis no need to check the electrolyte orto add distilled water.

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Never attempt to remove the bat-tery cell seals, as this would per-manently damage the battery.

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8Electrolyte is poisonous anddangerous since it containssulfuric acid, which causessevere burns. Avoid any con-tact with skin, eyes or clothingand always shield your eyeswhen working near batteries.In case of contact, administerthe following FIRST AID.99 EXTERNAL: Flush with plen-

ty of water.

99 INTERNAL: Drink large quan-tities of water or milk andimmediately call a physician.

99 EYES: Flush with water for15 minutes and seek promptmedical attention.

8 Batteries produce explosivehydrogen gas. Therefore, keepsparks, flames, cigarettes,etc., away from the battery andprovide sufficient ventilationwhen charging it in anenclosed space.

8 KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.


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To charge the batteryHave a Yamaha dealer charge thebattery as soon as possible if itseems to have discharged. Keep inmind that the battery tends to dis-charge more quickly if the motorcycleis equipped with optional electricalaccessories.

To store the battery1. If the motorcycle will not be used

for more than one month,remove the battery, fully chargeit, and then place it in a cool, dryplace.

2. If the battery will be stored formore than two months, check itat least once a month and fullycharge it if necessary.

3. Fully charge the battery beforeinstallation.

4. After installation, make sure thatthe battery leads are properlyconnected to the battery termi-nals.

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8 Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.

8 To charge a sealed-type (MF)battery, a special (constant-voltage) battery charger isrequired. Using a conventionalbattery charger will damagethe battery. If you do not haveaccess to a sealed-type (MF)battery charger, have aYamaha dealer charge yourbattery.

EAU01876

Replacing the fuseThe fuse box is located under theseat. (See page 3-12 for seatremoval and installation procedures.)If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF” and turnoff all electrical circuits.

2. Remove the blown fuse, andthen install a new fuse of thespecified amperage.

1

2

1. Fuse2. Spare fuse

Specified fuse: 20 A


6-34


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Do not use a fuse of a higheramperage rating than recommend-ed to avoid causing extensivedamage to the electrical systemand possibly a fire.

3. Turn the key to “ON” and turn onthe electrical circuits to check ifthe devices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU01079

Replacing a headlight bulbThis motorcycle is equipped withquartz bulb headlights. If a headlightbulb burns out, replace it as follows.

1. Remove cowling A. (See page 6-6 for cowling removal andinstallation procedures.)

2. Disconnect the headlight cou-pler, and then remove the head-light bulb cover.

3. Remove the headlight bulb hold-er according to the followingillustration, and then remove thedefective bulb.

NOTE:The removal procedure depends onthe type of bulb holder installed onyour motorcycle.

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Headlight bulbs get very hot.Therefore, keep flammable prod-ucts away from a lit headlight bulb,and do not touch the bulb until ithas cooled down.

4. Place a new bulb into position,and then secure it with the bulbholder.

2

1

2

1

1. Headlight coupler2. Headlight bulb cover

Type 1 Type 2

Type 3 Type 4

Turn Unhook

Unhook Turn


6-35


6

EC000105

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Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of thebulb, and the bulb life will beadversely affected. Thoroughlyclean off any dirt and fingerprintson the headlight bulb using a clothmoistened with alcohol or thinner.

5. Install the bulb cover, and thenconnect the coupler.

6. Install the cowling.

7. Have a Yamaha dealer adjustthe headlight beam if necessary.

EAU01078

Replacing the tail/brake lightbulb


2. Remove panel A. (See page 6-6 for panel removal and instal-lation procedures.)

a

a. Do not touch this area.


6-36


6

3. Remove the socket (togetherwith the bulb) by turning it coun-terclockwise.

4. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

5. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

6. Install the socket (together withthe bulb) by turning it clockwise.

7. Install the panel and the seat.

EAU03497

Replacing a turn signal lightbulb

1. Remove the turn signal light lensby removing the screw.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrew.

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Do not overtighten the screw, oth-erwise the lens may break.

11

2

1

1. Socket 1. Lens2. Screw

1. Bulb


6-37


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EAU01579

Supporting the motorcycleSince this model is not equipped witha centerstand, follow these precau-tions when removing the front andrear wheel or performing other main-tenance requiring the motorcycle tostand upright. Check that the motor-cycle is in a stable and level positionbefore starting any maintenance. Astrong wooden box can be placedunder the engine for added stability.

To service the front wheel1. Stabilize the rear of the motorcy-

cle by using a motorcycle standor, if an additional motorcyclestand is not available, by placinga jack under the frame in front ofthe rear wheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheelRaise the rear wheel off the groundby using a motorcycle stand or, if amotorcycle stand is not available, byplacing a jack either under each sideof the frame in front of the rear wheelor under each side of the swingarm.

EAU03239

Front wheelTo remove the front wheel

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8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so that there is no dangerof it falling over.

1. Disconnect the speedometercable from the front wheel.

1

1. Speedometer cable


6-38


6

2. Loosen the front wheel axlepinch bolt, then the wheel axle.

3. Lift the front wheel off the groundaccording to the procedure onpage 6-37.

4. Pull the wheel axle out, and thenremove the wheel.

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Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU04273

To install the front wheel Installing

1. Install the speedometer gear unitinto the wheel hub so that theprojections mesh with the slots.

2. Lift the wheel up between thefork legs.

NOTE:Make sure that there is enoughspace between the brake padsbefore inserting the brake disc andthat the slot in the speedometer gearunit fits over the retainer on the forkleg.

3. Insert the wheel axle.4. Lower the front wheel so that it is

on the ground.5. Tighten the wheel axle to the

specified torque.

6. Tighten the front wheel axlepinch bolt to the specified torque.

7. Push down hard on the handle-bar several times to check forproper fork operation.

21

1

1

1. Pinch bolt2. Wheel axle

1. Speedometer gear unit 1. Retainer

Tightening torque:Wheel axle:

59 Nm (5.9 m0kgf)


6-39


6

8. Connect the speedometer cable.

EAU03755

Rear wheelTo remove the rear wheel

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8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so that there is no dangerof it falling over.

1. Loosen the axle nut.

2. Lift the rear wheel off the groundaccording to the procedure onpage 6-37.

3. Remove the axle nut.4. Loosen the locknut and the drive

chain slack adjusting nut on eachend of the swingarm.

5. Push the wheel forward, andthen remove the drive chain fromthe rear sprocket.

NOTE:The drive chain does not need to bedisassembled in order to remove andinstall the wheel.

12 3

1. Axle nut2. Locknut3. Adjusting nut

Tightening torque:Front wheel axle pinch bolt:

20 Nm (2.0 m0kgf)


6-40


6

6. While supporting the brakecaliper, pull the wheel axle out.

7. Remove the wheel.ECA00048

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Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU01620

To install the rear wheel1. Install the brake caliper onto the

swingarm as shown.

NOTE:Make sure that the slot in the brakecaliper bracket fits over the retaineron the swingarm.

2. Install the drive chain onto therear sprocket.

3. Insert the wheel axle from theleft-hand side, install the axlenut, and then lower the rearwheel so that it is on the ground.

NOTE:Make sure that there is enoughspace between the brake padsbefore inserting the brake discbetween the brake pads.

4. Adjust the drive chain slack.(See page 6-26 for drive chainslack adjustment procedures.)

5. Tighten the axle nut to the speci-fied torque.

1

1. Retainer

Tightening torque:Axle nut:

104 Nm (10.4 m0kgf)


6-41


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EAU03087

TroubleshootingAlthough Yamaha motorcyclesreceive a thorough inspection beforeshipment from the factory, troublemay occur during operation. Anyproblem in the fuel, compression, orignition systems, for example, cancause poor starting and loss ofpower.The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systems your-self. However, should your motorcy-cle require any repair, take it to aYamaha dealer, whose skilled techni-cians have the necessary tools,experience, and know-how to servicethe motorcycle properly.Use only genuine Yamaha replace-ment parts. Imitation parts may looklike Yamaha parts, but they are ofteninferior, have a shorter service lifeand can lead to expensive repairbills.


6-42


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EAU01581

Troubleshooting chartsStarting problems or poor engine performance

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Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns overquickly.

The engine turns overslowly.

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter.


6-43


6

NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommendedcoolant as soon as possible.

Engine overheatingEW000070

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8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may beblown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

8 After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and thenslowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When thehissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove thecap.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is OK.

The coolant level is low.Check the cooling systemfor leakage.

Have a Yamaha dealer checkand repair the cooling system.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system.

There isleakage.

There is no leakage.


7-1

EAU03521

MOTORCYCLE CARE AND STORAGE

7

CareWhile the open design of a motorcy-cle reveals the attractiveness of thetechnology, it also makes it more vul-nerable. Rust and corrosion candevelop even if high-quality compo-nents are used. A rusty exhaust pipemay go unnoticed on a car, however,it detracts from the overall appear-ance of a motorcycle. Frequent andproper care does not only complywith the terms of the warranty, but itwill also keep your motorcycle lookinggood, extend its life and optimize itsperformance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and cov-ers as well as all electrical cou-plers and connectors, includingthe spark plug cap, are tightlyinstalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply suchproducts onto seals, gaskets,sprockets, the drive chain andwheel axles. Always rinse the dirtand degreaser off with water.

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8 Avoid using strong acidicwheel cleaners, especially onspoked wheels. If such prod-ucts are used on hard-to-remove dirt, do not leave thecleaner on the affected areaany longer than instructed.Also, thoroughly rinse the areaoff with water, immediately dryit, and then apply a corrosionprotection spray.

8 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergentand water to clean plastic.


7-2


7

8 Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abra-sive cleaning products, sol-vent or thinner, fuel (gasoline),rust removers or inhibitors,brake fluid, antifreeze or elec-trolyte.

8 Do not use high-pressurewashers or steam-jet cleanerssince they cause water seep-age and deterioration in thefollowing areas: seals (ofwheel and swingarm bearings,fork and brakes), electric com-ponents (couplers, connec-tors, instruments, switchesand lights), breather hosesand vents.

8 For motorcycles equippedwith a windshield: Do not usestrong cleaners or hardsponges as they will causedulling or scratching. Somecleaning compounds for plas-tic may leave scratches on thewindshield. Test the producton a small hidden part of thewindshield to make sure that itdoes not leave any marks. Ifthe windshield is scratched,use a quality plastic polishingcompound after washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottle-brush for hard-to-reach areas.Stubborn dirt and insects will comeoff more easily if the area is coveredwith a wet cloth for a few minutesbefore cleaning.

After riding in the rain, near the seaor on salt-sprayed roadsSince sea salt or salt sprayed onroads during winter are extremelycorrosive in combination with water,carry out the following steps aftereach ride in the rain, near the sea oron salt-sprayed roads.

NOTE:Salt sprayed on roads in the wintermay remain well into spring.

1. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.

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Do not use warm water since itincreases the corrosive action ofthe salt.

2. Apply a corrosion protectionspray on all metal, includingchrome- and nickel-plated, sur-faces to prevent corrosion.


7-3


7

After cleaning1. Dry the motorcycle with a

chamois or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermallyinduced discoloring of stainless-steel exhaust systems can beremoved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal, includ-ing chrome- and nickel-plated,surfaces.

5. Use spray oil as a universalcleaner to remove any remainingdirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry complete-ly before storing or covering it.

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8 Make sure that there is no oilor wax on the brakes or tires.If necessary, clean the brakediscs and brake linings with aregular brake disc cleaner oracetone, and wash the tireswith warm water and a milddetergent.

8 Before operating the motorcy-cle test its braking perfor-mance and cornering behav-ior.

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8 Apply spray oil and wax spar-ingly and make sure to wipeoff any excess.

8 Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

8 Avoid using abrasive polish-ing compounds as they willwear away the paint.

NOTE:Consult a Yamaha dealer for adviceon what products to use.


7-4


7

StorageShort-termAlways store your motorcycle in acool, dry place and, if necessary, pro-tect it against dust with a porouscover.

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8 Storing the motorcycle in apoorly ventilated room or cov-ering it with a tarp, while it isstill wet, will allow water andhumidity to seep in and causerust.

8 To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle forseveral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float cham-ber by loosening the drain bolt;this will prevent fuel depositsfrom building up. Pour thedrained fuel into the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps toprotect the cylinder, piston rings,etc. from corrosion.

a. Remove the spark plug capand spark plug.

b. Pour a teaspoonful of engineoil into the spark plug bore.

c. Install the spark plug cap ontothe spark plug, and then placethe spark plug on the cylinderhead so that the electrodesare grounded. (This will limitsparking during the next step.)

d. Turn the engine over severaltimes with the starter. (Thiswill coat the cylinder wall withoil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

EWA00003

w

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turn-ing the engine over.


7-5


7

6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground.Alternatively, turn the wheels alittle every month in order to pre-vent the tires from becomingdegraded in one spot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once amonth. Do not store the batteryin an excessively cold or warmplace (less than 0 °C) or morethan 30 °C). For more informa-tion on storing the battery, seepage 6-33.

NOTE:Make any necessary repairs beforestoring the motorcycle.


8-1

EAU01038

SPECIFICATIONS

8

Model TDR125

Dimensions

Overall length 2,120 mm(F, GB, IRL, B, P, GR, E)

2,185 mm (S, SF, D, CH, A)

Overall width 840 mm

Overall height 1,295 mm

Seat height 850 mm

Wheel base 1,405 mm

Ground clearance 270 mm

Minimum turning radius 2,200 mm

Basic weight (with oil and fullfuel tank) 135 kg

136 kg (CH, A)

Engine

Engine type Liquid cooled 2-stroke,gasoline

Cylinder arrangement Forward inclined singlecylinder

Displacement 125 cm3

Bore × Stroke 56.0 × 50.7 mm

Compression ratio 6.6:1

Starting system Electric starter

Lubrication system Separate lubrication(Yamaha Autolube)

Engine oil (2-cycle)

Type Yamalube 2 or equivalent2-stroke engine oil

Capacity

Total amount 1.2 L

Transmission oil

Type SAE 10W30 SE motor oil

Capacity

Periodic oil change 0.75 L

Total amount 0.8 L

Cooling system capacity(total amount) 1.05 L

Air filter Wet type element

Fuel

Type REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity 11 L

Reserve amount 2.2 L

Carburetor

Manufacturer MIKUNI

Model × quantity TM28SS × 1

Specifications


8-2

SPECIFICATIONS

8

Spark plug

Manufacturer/model NGK/BR9ES

Spark plug gap 0.7–0.8 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Helical gear

Primary reduction ratio 71/22 (3.227)

Secondary reduction system Chain drive

Secondary reduction ratio 3.563

Number of drive chainsprocket teeth (rear/front) 57/16

Transmission type Constant mesh 6-speed

Operation Left foot

Gear ratio 1st 2.833

2nd 1.875

3rd 1.412

4th 1.143

5th 0.957

6th 0.818

Chassis

Frame type Semi double cradle

Caster angle 26°

Trail 116 mm

Tires

Front

Type Tubeless

Size 100/90-18 56P or100/90-18 M/C 56P

Manufacturer/ BRIDGESTONE / TW53model DUNLOP / D602F

Rear

Type Tubeless

Size 130/80-17 65P or130/80-17 M/C 65P

Manufacturer/ BRIDGESTONE / TW54model DUNLOP / D602

Maximum load* 180 kg179 kg (CH, A)

Air pressure (cold tire)up to 90 kg load*

Front 175 kPa (1.75 kgf/cm2, 1.75 bar)

Rear 200 kPa (2.00 kgf/cm2, 2.00 bar)

90 kg load–Maximumload*

Front 175 kPa (1.75 kgf/cm2, 1.75 bar)

Rear 225 kPa (2.25 kgf/cm2, 2.25 bar)* Total weight of rider, passenger, cargo and accessories


8-3

SPECIFICATIONS

8

Wheels

Front

Type Cast

Size 18 × MT2.15 or

18 M/C × MT2.15

Rear

Type Cast

Size 17 × MT2.50 or

17 M/C × MT2.50

Brakes

Front

Type Single disc brake

Operation Right hand

Fluid DOT 4

Rear

Type Single disc brake

Operation Right foot

Fluid DOT 4

Suspension

Front

Type Telescopic fork

Rear

Type Swingarm (Monocross)

Spring/shock absorber

Front

Type Coil spring/oil damper

Rear

Type Coil-gas spring/oil damper

Wheel travel

Front 180 mm

Rear 180 mm

Electrical

Ignition system C.D.I.

Charging system

Type A.C. magneto

Standard output 14 V, 12A @ 5,000 r/min

Battery

Type YTX5L-BS

Voltage, capacity 12 V, 4 Ah


8-4

SPECIFICATIONS

8

Headlight type Quartz bulb (halogen)

Bulb voltage, wattage × quantity

Headlight 12 V, 60/55W × 212 V, 35/35W × 2 (GB, IRL)

Tail/brake light 12 V, 5/21W × 2

Front turn signal light 12 V, 21W × 2

Rear turn signal light 12 V, 21W × 2

Auxiliary light 12 V, 4W × 2

12 V, 3.4W × 2 (GB, IRL)

Meter lighting 12 V, 3.4W × 3

Neutral indicator light 12 V, 3.4W × 1

High beam indicator light 12 V, 3.4W × 1

Oil level warning light 12 V, 3.4W × 1

Turn indicator light 12 V, 3.4W × 1

Fuse 20A


8-5

SPECIFICATIONS

8

EAU03941

Conversion tableAll specification data in this manual are listed in SI andMETRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in2 mm × 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m•kgf 7.233 ft•lb

Torque m•kgf 86.794 in•lb

cm•kgf 0.0723 ft•lb

cm•kgf 0.8679 in•lb

Weightkg 2.205 lb

g 0.03527 oz

Speed km/hr 0.6214 mph

km 0.6214 mi

m 3.281 ft

Distance m 1.094 yd

cm 0.3937 in

mm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)

Volume/ cc (cm3) 0.06102 cu•in

Capacity L (liter) 0.8799 qt (IMP liq.)

L (liter) 0.2199 gal (IMP liq.)

kgf/mm 55.997 lb/in

Misc. kgf/cm2 14.2234 psi (lb/in2)

Centigrade (°C) 9/5+32 Fahrenheit (°F)


9-1

EAU01039

CONSUMER INFORMATION

9

EAU02944

Identification numbersRecord the key identification number,vehicle identification number andmodel label information in the spacesprovided below for assistance whenordering spare parts from a Yamahadealer or for reference in case thevehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATIONNUMBER:

3. MODEL LABEL INFORMATION:

EAU01041

Key identification numberThe key identification number isstamped into the key tag.Record this number in the space pro-vided and use it for reference whenordering a new key.

EAU01043

Vehicle identification numberThe vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority inyour area.

1 1

1. Key identification number 1. Vehicle identification number

1

6


9-2

CONSUMER INFORMATION

9

EAU01050

Model labelThe model label is affixed to theframe under the seat. (See page 3-12 for seat removal and installationprocedures.) Record the informationon this label in the space provided.This information will be needed whenordering spare parts from a Yamahadealer.

1

1. Model label


PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2001·7–0.1×1(E) !

YAMAHA MOTOR CO., LTD.

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